Generac Power Systems 6500EXL Manuel utilisateur

Portable Generator Owner’s Manual

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

Model No. 9798-2 (6,500 Watt AC Generator) Manual No. B2649 Revision 3 (06/01/2001)

Visit our Generac website: www.generac-portables.com

Problems?

Questions?

Before taking your unit

back to the store,

call the generator

helpline at

1–800–270–1408

M–F 8–5 CT

6500EXL

Generac Portable Products 6500EXL Extended Life Generator

EQUIPMENT

DESCRIPTION

This generator is an engine–driven, revolving field,

alternating current (AC) generator. It was designed to

supply electrical power for operating compatible electrical

lighting, appliance, tools and motor loads.This manual

contains information for a generator that operates

120 and/or 240 Volt, single phase, 60 Hz devices that

require up to 6,500 watts (6.5 kW) of power that pull up

to 54.2 Amps at 120 Volts or 27.1 Amps at 240 Volts.

CAUTION! Do Not exceed the generator’s

wattage/amperage capacity.The total load should not be

greater than 6,500 watts. See “Don’t Overload the

Generator” on page 11.

The generator’s revolving field is driven at about 3,600 rpm

by a single-cylinder engine.

Every effort has been made to ensure that information in

this manual is accurate and current. However, Generac

reserves the right to change, alter or otherwise improve the

product and this document at any time without prior

notice.

CAUTION! Do Not tamper with engine

governed speed. High operating speeds are

dangerous and increase risk of personal injury or

damage to equipment.The generator supplies

correct rated frequency and voltage only when

running at proper governed speed. Incorrect

frequency and/or voltage can damage some

connected electrical loads. Operating at excessively

low speeds imposes a heavy load.When adequate

engine power is not available engine life may be

shortened.

The Emission Control System for this generator is

warranted for standards set by the Environmental

Protection Agency. For warranty information refer to the

engine owner’s manual.

SAFETY RULES

This generator set was designed and manufactured for

specific applications. Do Not attempt to modify the unit or

use it for any application it was not designed for. If you have

any questions about your generator’s application, ask your

dealer or consult the factory.

The manufacturer could not possibly anticipate every

circumstance that might involve a hazard. For that reason

warnings in the manual and warnings on tags or decals

affixed to the unit are not all–inclusive. If you intend to

handle, operate or service the unit by a procedure or

method not specifically recommended by the manufacturer,

first make sure that such a procedure or method will not

render this equipment unsafe or pose a threat to you and

others.

Read this manual carefully and become familiar

with your generator set. Know its applications, its

limitations and any hazards involved.

DANGER! You must isolate the generator from

the electric utility using approved transfer

equipment if this unit is used for backup power.

Failure to isolate the generator from the

power utility may result in injury or death to

electric utility workers and damage to the

generator due to a backfeed of electrical energy.

Whenever unit is providing backup power, the

electric utility must be notified.

DANGER! Generator exhaust gases contain

DEADLY carbon monoxide gas. If breathed in

sufficient concentrations, carbon monoxide

can cause unconsciousness or death. Operate

this equipment outdoors where adequate ventilation

is available.

The engine exhaust from this product contains

chemicals known to the State of California to

cause cancer, birth defects, or other reproductive

harm.

WARNING:

Generac Portable Products 6500EXL Extended Life Generator

• The generator produces a very powerful voltage that can

cause serious injury or death by electrocution. Never

touch bare wires or receptacles. Never permit a child or

any unqualified person to operate the generator.

•Never handle any kind of electrical cord or device while

standing in water, while barefoot or while hands or feet

are wet. Death or serious injury from electrocution may

result.

• Use a ground fault circuit interrupter (GFCI) in any damp

or highly conductive area (such as metal decking or steel

work).

•Never use worn, bare, frayed or otherwise damaged

electrical cords with the generator. Death, serious injury

and property damage from electrical shock may result.

•Gasoline is highly FLAMMABLE and its vapors are

EXPLOSIVE. Never allow smoking, open flames,

sparks or heat in the vicinity while handling

gasoline. Avoid spilling gasoline on a hot engine. Comply

with all laws regulating storage and handling of gasoline.

•Do Not overfill the fuel tank.Always allow room for fuel

expansion. If tank is overfilled, fuel can overflow

onto a hot engine and cause a FIRE or an

EXPLOSION.

•Never store a generator with fuel in the tank where

gasoline vapors might reach an open flame, spark or pilot

light (as on a furnace, water heater, clothes dryer). FIRE

or an EXPLOSION may result.

• The unit requires an adequate flow of cooling air for its

continued proper operation. Never operate the unit

inside any room or enclosure where the free flow of

cooling air into and out of the unit might be obstructed.

Allow at least 2 feet of clearance on all sides of generator,

even while operating unit outdoors, or you could damage

the unit.

•Never start, or stop the unit with electrical loads

connected to receptacles with the connected devices

turned ON. Start the engine and let it stabilize before

connecting any electrical loads. Disconnect all electrical

loads before shutting down the generator.

•Do Not insert any object through cooling slots of the

engine.You could damage the unit or injure yourself.

•Never operate the generator:

in rain; in any enclosed compartment; when connected

electrical devices overheat; if electrical output is lost; if

engine or generator sparks; if flame or smoke is observed

while unit is running; if unit vibrates excessively.

GROUNDING THE

GENERATOR

The National Electrical Code requires that the frame and

external electrically conductive parts of this generator be

properly connected to an approved earth ground. Local

electrical codes may also require proper grounding of the

unit. For that purpose, a GROUNDING WING NUT is

provided on the generator end (Figure 1).

Generally, connecting a No. 12 AWG (American Wire

Gauge) stranded copper wire to the grounding wing nut

and to an earth–driven copper or brass grounding rod

(electrode) provides adequate protection against electrical

shock. Be careful to keep the grounding wire attached after

connecting the stranded copper wire. However, local codes

may vary widely. Consult with a local electrician for

grounding requirements in your area.

Properly grounding the generator helps prevent electrical

shock if a ground fault condition exists in the generator or

in connected electrical devices. Proper grounding also helps

dissipate static electricity, which often builds up in

ungrounded devices.

Figure 1 — Grounding Wing Nut

Grounding Wing Nut

Generac Portable Products 6500EXL Extended Life Generator

Your generator requires some assembly and is ready for

use after it has been properly serviced with the

recommended oil and fuel.

If you have any problems with the assembly of your

generator, please call the generator helpline at

1-800-270-1408.

IMPORTANT: Any attempt to run the unit before it has

been serviced with the recommended oil will result in an

engine failure.

REMOVE GENERATOR

FROM CARTON

• Set the carton on a rigid flat surface with “This Side Up”

arrows pointing upward.

• Carefully open the top flaps of the shipping carton.

Review “Cold Weather Operation” on page 9.

• Cut down corners at one end of carton from top to

bottom and lay that side of carton down flat.

• Remove all packing material, carton fillers, etc.

• Remove the generator from the shipping carton.

CARTON CONTENTS

Check all contents. If any parts are missing or damaged, call

the generator helpline at 1-800-270-1408.

• The generator

• Electric start battery cables

• Generator and engine owner’s manuals

• Locking 30 Amp plugs

• Battery charge cables

• Battery tray mounting bracket/hardware

• Spare spark plug and air filter element

• Spark plug wrench

INSTALLING TRAY AND

BATTERY

You must purchase and install a 12Volt DC battery (Series

U1L).The battery should be serviced with electrolyte fluid

and fully charged prior to installation. Install the battery as

follows:

• Find the battery tray and fasteners shipped loose in the

carton.

• Remove the four battery tray screws from cradle.

• Position the battery tray and install with supplied

hardware (see Figure 2).

• Set battery onto tray.

• Retain battery to tray with one battery hold down

bracket, two J bolts, two lock washers, two flat washers

and two hex nuts (Figure 3).

Figure 3 — Secure 12 Volt Battery

Figure 2 — Install Battery Tray

Generac Portable Products 6500EXL Extended Life Generator

• Connect the red battery cable from the engine starter

switch to positive (+) terminal on the battery

(Figure 4).

• Connect the black battery cable to the negative (–)

terminal on the battery (Figure 4).

• Connect the other end of the black cable to the engine,

not the frame (Figure 4).

CAUTION! Be sure the BLACK cable is connected to

the engine mount and not the frame.You could damage the

ground wire.

BEFORE STARTING THE

ENGINE

Add Oil

CAUTION! Any attempt to crank or start the engine

before it has been properly filled with the recommended

oil may result in an engine failure.

To fill your engine with oil:

• Place generator on a level surface.

• Follow the oil grade recommendations and oil fill

instructions given in the engine owner’s manual.

NOTE: The generator’s revolving field rides on a

prelubricated and sealed ball bearing that requires no

additional lubrication for the life of the bearing.

Add Gasoline

WARNING! Never fill fuel tank indoors. Never

fill fuel tank when engine is running or hot. Do Not

light a cigarette or smoke when filling the fuel tank.

WARNING! Do Not overfill the fuel tank.

Always allow room for fuel expansion.

• Use regular UNLEADED gasoline with the generator

engine. Do Not use premium gasoline. Do Not mix oil

with gasoline.

• Clean area around fuel fill cap, remove cap.

• Slowly add unleaded regular gasoline to fuel tank. Be

careful not to overfill.Allow about 1/2" of tank space for

fuel expansion (Figure 5).

• Install fuel cap and wipe up any spilled gasoline.

IMPORTANT: It is important to prevent gum deposits from

forming in essential fuel system parts, such as the carburetor,

fuel filter, fuel hose or tank during storage.Also, experience

indicates that alcohol–blended fuels (called gasohol, ethanol

or methanol) can attract moisture, which leads to separation

and formation of acids during storage.Acidic gas can damage

the fuel system of an engine while in storage.

To avoid engine problems, the fuel system should be

emptied before storage of 30 days or longer. See “Storage”

on page 12. Never use engine or carburetor cleaner

products in the fuel tank or permanent damage may occur.

Figure 4 — Wire Connections

RED wire from

starter switch

BLACK wire

from battery Figure 5 — Typical Fuel Expansion Space

Generac Portable Products 6500EXL Extended Life Generator

12 Volt DC,10 Amp Receptacle — Recharge a

discharged 12 Volt automotive type battery through this

receptacle.

120 Volt AC, 20 Amp, Duplex Receptacle — May be

used to supply electrical power for the operation of

120 Volt AC, 20 Amp, single phase, 60 Hz electrical lighting,

appliance, tool and motor loads.

120 Volt AC, 30 Amp Locking Receptacle — May be

used to supply electrical power for the operation of

120 Volt AC, 30 Amp, single phase, 60 Hz electrical lighting,

appliance, tool and motor loads.

120/240 Volt AC, 30 Amp Locking Receptacle — May

be used to supply electrical power for the operation of

120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz

electrical lighting, appliance, tool and motor loads.

Air Cleaner — Uses a dry type filter element and foam

pre–cleaner to limit the amount of dirt and dust sucked

into the engine.

Choke Lever — Used when starting a cold engine.

Circuit Breakers (AC) — Each receptacle is provided

with a "push to reset" circuit breaker to protect the

generator against electrical overload.

Fuel Tank — Capacity of seven (7) U.S. gallons.

Grounding Wing Nut — Used for proper grounding of

unit.

Idle Control Switch — With this switch set to ON,

printed circuit board in control panel automatically reduces

engine speed when no load is connected and increases

engine to proper speed when load is applied. However, be

sure switch is OFF when starting engine.

Recoil starter — Used to start the engine.

Run/Stop Switch — Set this switch to "Run" before

using recoil starter. Set switch to "Stop" to switch OFF

engine.

Spark Arrester Muffler — Exhaust muffler lowers

engine noise and is equipped with a spark arrester screen.

KNOWYOUR GENERATOR

Read this owner’s manual and safety rules before operating your generator.

Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and

adjustments. Save this manual for future reference.

120 Volt AC, 20 Amp

Duplex Receptacle

Fuel Tank

Idle Control Switch

Choke Lever

Recoil Starter

12 Volt DC, 10 Amp

Receptacle

Run/Stop Switch

120 Volt AC, 30 Amp

Receptacle

Circuit Breakers (AC)

120/240 Volt AC,

30 Amp Receptacle

Spark Arrester Muffler

Air Cleaner

Grounding Wing Nut

Generac Portable Products 6500EXL Extended Life Generator

OPERATING THE

GENERATOR

CAUTION! Never start or stop the engine with

electrical loads connected to the receptacles AND

with the connected devices turned ON.

Starting the Engine

• Unplug all electrical loads from generator receptacles

before starting the engine.

• Make sure the unit is in a level position.

• Open the fuel shut–off valve (Figure 6).

• Make sure the Idle Control switch is “Off”.

• Place Run/Stop switch in the “Run” position (Figure 7).

• Place the choke lever in the “Full” choke position by

sliding it to the left toward the valve cover in the

direction indicated by the arrow (Figure 8).

• Grasp starter grip and pull slowly until you feel slight

resistance, then pull quickly.Do Not let handle “snap-

back” into recoil housing.

• When engine starts, move choke lever to “Run” position

by sliding it all the way to the right (away from the valve

cover and under the arrow).

NOTE: If engine fails to start after 3 pulls, move the choke

lever to “Half” choke position and pull starter rope again

2 times.

NOTE: If the engine still fails to start, review the engine

owner’s manual.Also, check for proper oil level in

crankcase. Unit is equipped with a low oil shutdown

system. See engine owner’s manual for information

regarding the low oil shutdown system.

Connecting Electrical Loads

• Let engine stabilize and warm up for a few minutes after

starting.

• Plug in and turn on the desired 120 and/or 240 Volt AC,

single phase, 60 Hz electrical loads.

•Do Not connect 240 Volt loads to the 120 Volt

receptacles.

•Do Not connect 3–phase loads to the generator.

•Do Not connect 50 Hz loads to the generator.

•DO NOT OVERLOAD THE GENERATOR. Add up

the rated watts (or amps) of all loads to be connected at

one time.This total should not be greater than the rated

wattage/amperage capacity of the generator. See “Don’t

Overload the Generator” on page 11.

Figure 6 — Fuel Shut-offValve

Figure 7 — Run/Stop Switch

Figure 8 — Choke Lever

Generac Portable Products 6500EXL Extended Life Generator

Stopping the Engine

• Unplug all electrical loads from generator panel

receptacles. Never start or stop engine with electrical

devices plugged in and turned on.

• Put the idle control switch in the “Off” position.

• Let engine run at no–load for 30 seconds to stabilize the

internal temperatures of engine and generator.

• Move run/stop switch to “Stop”.

• Close the fuel shut–off valve.

Operating Automatic Idle Control

This switch is designed to greatly improve fuel economy.

When this switch is turned ON, the engine will only

run at its normal high governed engine speed when an

electrical load is connected.When an electrical load is

removed, the engine will run at a reduced speed. With the

switch off, the engine will run at the normal high engine

speed. Always have the switch off when starting and

stopping the engine.

Charging a Battery

WARNING! Storage batteries give off explosive

hydrogen gas while recharging.An explosive mixture

will remain around the battery for a long time after

it has been charged.The slightest spark can ignite

the hydrogen and cause an explosion, resulting in

blindness or other serious injury.

WARNING! Do Not permit smoking, open

flame, sparks or any other source of heat around a

battery.Wear protective goggles, rubber apron and

rubber gloves when working around a battery.

Battery electrolyte fluid is an extremely caustic

sulfuric acid solution that can cause severe burns. If

spill occurs flush area with clear water immediately.

Your generator has the capability of recharging a discharged

12 Volt automotive or utility style storage battery. Do Not

use the unit to charge any 6Volt batteries. Do Not use the

unit to crank an engine having a discharged battery.

To recharge 12Volt batteries, proceed as follows:

• Check fluid level in all battery cells. If necessary, add

ONLY distilled water to cover separators in battery cells.

Do Not use tap water.

• If the battery is equipped with vent caps, make sure they

are installed and are tight.

• If necessary, clean battery terminals.

• Connect battery charge cable connector plug to panel

receptacle identified by the words “12 VOLTS D.C.”

• Connect battery charge cable clamp with red handle to

the positive (+) battery terminal (Figure 9).

• Connect battery charge cable clamp with black handle

to the negative (–) battery terminal (Figure 9).

• Start engine. Let the engine run while battery recharges.

• When battery has charged, shut down engine

NOTE: Use an automotive hydrometer to test battery

state of charge and condition. Follow the hydrometer

manufacturer’s instructions carefully. Generally, a battery is

considered to be at 100% state of charge when specific

gravity of its fluid (as measured by hydrometer) is 1.260 or

higher.

Figure 9 — Battery Connections

Generac Portable Products 6500EXL Extended Life Generator

COLD WEATHER

OPERATION

Under certain weather conditions (temperatures below

40°F [4°C] and a high dew point), your generator may

experience icing of the carburetor and/or the crankcase

breather system.

In an emergency, use the original shipping box as a

temporary shelter:

• Cut off all flaps.

• Cut out one of the long sides of the box to expose

exhaust side of unit. Ensure a minimum of two feet

clearance between open side of box and nearest object.

• Cut appropriate slots to access receptacles of unit.

• Start unit, then place box over it.

IMPORTANT: Remove shelter when temperature is

above 40°F [4°C].

For a more permanent shelter, build a structure that will

enclose three sides and the top of the generator:

• Make sure entire muffler-side of generator is exposed.

Note that your generator may appear different from that

shown in Figure 10.

• Ensure a minimum of two feet clearance between open

side of box and nearest object.

• Face exposed end away from wind and elements.

• Enclosure should hold enough heat created by the

generator to prevent problems.

CAUTION!Neverrun unit indoors. Do Not

enclose generator any more than shown.

RECEPTACLES

120/240 Volt AC, 30 Amp, Locking

Receptacle

Use a NEMA L14–30 plug with this receptacle. Connect a

4–wire cord set rated for 250 Volt AC loads at 30 Amps (or

greater) (Figure 11).You can use the same 4–wire cord if

you plan to run a 120Volt load.

This receptacle powers 120/240Volt AC, 60 Hz, single

phase loads requiring up to 3,600 watts of power at

30 Amps for 120 Volts; 6,500 watts of power (6.5 kW) at

30 Amps for 240 Volts.The outlet is protected by a 30 Amp

push–to–reset circuit breaker.

CAUTION! Although this outlet states it has a

240 Volt 30 Amp rating (up to 7,200 watts), the

generator is only rated for 6,500 watts. Powering

loads that exceed the wattage/amperage capacity of

the generator can damage it or cause serious

injuries.

120 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L5–30 plug with this receptacle. Connect a

3–wire cord set rated for 125 Volt AC loads at 30 Amps to

the plug (Figure 12).

Figure 10 — Temporary Cold Weather Shelter

Wind

Figure 11 — 120/240 Volt AC, 30 Amp, Locking Receptacle

Use this receptacle to operate 120Volt AC, 60 Hz, single

phase loads requiring up to 3,600 watts (3.6 kW) of power

at 30 Amps.The outlet is protected by a 30 Amp

push–to–reset circuit breaker.

120 Volt AC, 20 Amp, Duplex

Receptacle

Each receptacle (Figure 13) is protected against overload by

a 20 Amp push–to–reset circuit breaker.

Use each receptacle to operate 120Volt AC, single–phase,

60 Hz electrical loads requiring up to 2,400 watts (2.4 kW)

at 20 Amps of current. Use cord sets that are rated for

125 Volt AC loads at 20 Amps (or greater).

12 Volt DC, 10 Amp Receptacle

This receptacle allows you to recharge a 12 Volt

automotive or utility style storage battery with the battery

charge cables provided (Figure 14).This receptacle can not

recharge 6Volt batteries and can not be used to crank an

engine having a discharged battery. See the section

“Charging a Battery” (page 8) before attempting to

recharge a battery.

Generac Portable Products 6500EXL Extended Life Generator

Figure 12 — 120 Volt AC, 30 Amp, Locking Receptacle Figure 13 — 120 Volt AC, 20 Amp, Duplex Receptacle

Figure 14 — 12Volt DC, 10 Amp Receptacle

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